Mold



MW. 30, 1948. E. MAYER 2,454,819

Original Filed April 8. 1941 v 7 Sheets-Sheet 1 Nov. 30, 1948. E. MAYER- 54,

now I Original Filed April 8, 1941 Y '7 Sheds-$11691; 2 v

Nov". 30, 1948. E. MAYER I 2,454,819

' mom) Original Filed April 8,1941 I 7 Sheets-Sheet 3 N v. so, 1948. 54mm, 2,454,819

MOLD

Original Filed April 8, 1941 Sheets-Sheet 4 a? 4 Fly. 7

- NW. 30, 194s. E. MAYER I 2,454,819

MOLD

Original Filed April 8, 1941 7 $heets$heet 5 Ndv. 30, 1948. r E. MAYER 2,454,819

' l mom) Original Filed April 8, 1941 I '1 Sheets-Sheet 6 FllgJZ Swuwvbom ram-16 -j NOV. 30, 1948. E. M Y 2,454,819

' MOLD 0rigix 1al Filed April 8 1941 7 Sheets-Sheet 7 Patented Nov. so, 1948 A UNITED STATES- MOLD Ernest Mayer, Leipzig, Germany; vested in the Attorney General of the United States Original application April 8, 1941, Serial No. 387,531. Divided and this application January 12, 1945, Serial No. 572,575. In Germany November 25, 1939 6 Claims. (Cl. 22126) This invention relates to a mold for air-cooled ribbed cylinders, cylinder heads, or similar ribbed work.

It has been the prevailing practice hitherto to cast objects of this class in two-part molds produced with the aid of patterns. The production of such molds is, however, quite bothersome, protracted and difiicult and requires a skilled molder. Furthermore, as the narrow gaps between .the ribs or the pattern prohibit tamping down of the molding sand the latter must be loosely thrown in, and the rib-like mold parts have to be fitted with a large number of pins which often get out of line and have to be knocked out during cleaning whereby the casting may be damaged. The use of an ordinary mold involves, moreover, the drawback that a cylinder cast therein has a seam running around it and its appearance is as a rule not satisfactory. The half ribs are usually displaced relative to each other at the seams, and the casting is seldom accurate to size, because the pattern cannot be smoothly removed from the mold, particularly if the ribs are closely arranged and possess a slight wall thickness to insure effective cooling. Special difiiculties have also to be overcome at present in cleaning a casting fitted with closely adjacent thin ribs which break ofi easily, so that relatively much waste occurs. The necessity of getting the pattern out of the mold restricts the possibilities of shaping the part to be cast, and for this reason the shape and arrangement most favorable for instance to cooling must often be sacrificed.

It is known to employ in the casting of cylin der heads provided with cooling ribs'and intended for air-cooled engines a mold built up from superposed metallic core plates each pair of which forms the mold part-corresponding to a rib and which are divided in axial direction of the cyl-- inder, so that, owing to this longitudinal division, they can be withdrawn from the finished casting. A mold of this type, however, does not permit good shrinking of the casting and leaves therein a seam extending over the entire axial section. As the core plates have to be drawn out laterally, shapin of the ribs is restricted to a smooth form tapering off towards the outer-edge, and during the removal of the plates, which must be done while the casting is still semiplastic,.either the ribs or the casting is easily damaged;-

Compared with the known art, the'invention resides in providing for a mold of the type mentioned comprising fiat superposed plates of which two adjacent ones form the mold part corresponding to a rib core members produced in the sand asundivided plates in consequence whereof the casting can shrink without impediments'and has no seam. Apart from the very simple rib patterns required for the production of the core plates, no pattern for the casting is needed and the drawbacks connected with casting to pattern are eliminated. As the cores drop out by themselves and smooth surfaces are obtained, cleaning is greatly facilitated and often superfluous. Any desired shape may furthermore be imparted to the rib and casting, which'is particularly suited for cooling, such as a cruciform, wavelike, etc. shape. The production of the mold requires only a few simple core boxes, core pins canbe dispensed with entirely and in producing the mold parts limiting the hollow rib spaces the same may be stamped in the usual manner. There is moreover no seam, since the partin lines coincide with the edges ofthe ribs, The manufacture of the mold is considerably speeded up, because the platelike core members can be produced by unskilled female operators and the building up of'the mold from the plates does not offer any difficulties.

The platelike construction of the mold for an air-cooled engine cylinder or cylinder head provides moreover surprising possibilities for shaping the cooling ribs in an advantageous manner;

For example, the ribs may be provided with reiniforcing connectin flanges which'may be formed also of metal bars inserted in the core plates. Other advantages afforded by a mold according to the inventioncomprise the saving effected in sand and the elimination of molding pins. The invention further permits the manufacture of the core plates from iron borings or from a mixture of iron borings and sand instead of from pure sand so as to vary at will the hardness, grain and smoothness of the casting. If the core plates are made entirely from iron borings the cast material will resemble a chilled casting.

According to the invention the sand core plates are further inserted in ironor metal holding means or produced in annular or platelike iron or metal holders whose outer circumference exactly corresponds to the hollow section of the molding box. The metal plates, which may be repeatedly used, insure good fitting and accurate guiding of the core plates in the molding box asjywellgas the proper thickness of the latter, of the hollow molds for the'ribs and of the ribs of the casting to be made.

In numerous instances the sand core plates each of which is set in a metal plate may be used Wit out molding boxes, in which case the metal Of'Fig. 1;

like the core plates or their metal holding means being provided with means, as projections, etc., for alining and supporting the core plates.

The invention makes it possible tocast two or more cylinders on top of each other: in a single molding box and. thereby to save an upper and a lower core which serve for holding the gate and the core for the bore.

The mold according to the invention may be used also for connecting by casting the ribs made by a separate process with the cylinder liner cast in the mold. To this end the ribs are inserted in the hollow spaces formed by: two" adjacent core plates in such manner thatthe inner edges project into the hollow mold space serving for. form ing. the liner and during pouring of the metal are surrounded thereby; The mold may be employed also for casting the ribs; around a finished liner to which they are secured by shrinkingduring cooling of'the metaLthe liner being inserted as core in the mold.

Otherobjects of theinvention refer to details of construction, arrangement and production of the core plates limiting the hollow rib spaces, and to the efiectsresulting therefrom, as described in th'e'specification.

The invention is illustrated; byway of example in the accompanymg. drawing, in which Figures 1 and 2 show a cylinder moldaccorde ing to' the invention, Fig. L being a verticalpartial section in the direction of the cylinder axis and Fig; 2 a cross section on the'l-ine 2'--2,

Figs. 3 and i show a mold according tothe invention with inserted metal ribs, Fig.3 being apartial section through the cylinder axis and Fig. 4. a cross section on the. line 4-, of Fig; 3";

Fig- 5 is an axial section of a mold: for'casting a cylinder-head; and

Figs. 6 to 17 are detailtviews', partly'ineleva tior'r and partly in section, of the construction and arrangement or core plates;

- Figs; 1 to 4 showa moldiin which in a cylmdri cal molding box. l'- a number of platelike we members 3 are superposed; on. a core- 2; The: core members 3 are each made irom sand in an annular' metal plate 8 and with the aid of these plates whose circumferential shape is accurately adapted to the hollow section of the box I inserted in the latter, To preventiturningrtlie core plates 3 possess at one point of their circumference a that portion 4 corresponding to a ledgelike axially parallel reinforcernent 5- on'the fnside of the box t, which hasthe same cross-sectional form as the flat portions ofthe plates, whose inner edge and side faces are so constructed that two adjacent plates: always limit a hollow space 6 required for'forming acasting rib, as indicated in Fig. l.

At a slight distance from their outer edge thehollow spaces 6 are connected by openings 1 of the. core. plates 3,. whiol'iserve for forming the connecting and reinforcing members between the ribs of the casting. These members also be formed by'bars of suitable material which. are inserteo. the cp'eningsl..

Y In the construction' shown in: E'igs. 3- and! the hollow spaces serving for forming the ribs and limited by two core plates 3 are provided with inserted flat annular plates 9 whose outline and cross-sectional form exactly correspond to the shape of the ribs of the casting and which possess at their inner edge a projection ii! of dovetailed cross section, which extends into the hollow space i l of the mold intended for forming the cylinder wall. During the casting operation the projections l0 are embedded, in, or welded to, the cast metal of the cylinder wall.

The mold shown in Fig. 5 serves for a cylinder head. having difierently formed ribs which wholly or partially surround the cylinder in planes extending perpendicular to the cylinder axis and partly extend parallel to this axis, and comprises. a molding box l2 shown undivided in Fig. 5, though it may be made up also of two or more parts united by screws. In the box l2 sand cores 13 for forming the hollow spaces for the casing receiving the valve control mechanism are insorted, and between these core members core plates M are arranged in upright position on the bottoms of the box l2, two of said plates always forming the hollow molds 15 for the axially parallel extending cooling ribs. Each sand core plate H- is firmly united with a metal plate 16 whose outline coincides with that of the alining means of the box 12 and whose thickness generally corresponds to the thickness of the cast rib-on the outer edge'thereof.

As indicated in Figs. 6 and 7, the sand core plates M are produced on a flat side of the metal plate H5. The sand cor-e is firmly connected with the metal plate l6 by means of openings I T, It which are formed in the plate and may also be undercut to insure better anchoring of the sand, and of undercut projections l9 on the flat side where the sand core plate is formed, whose height together with the thickness of the plate i6 is equal to the spacing of the ribs plus the t'l'rickness thereof. The portion of the sand core plate [4' freely projecting beyond the inner edge of the metal plate It is preferably reinforced by radially disposed small metal plates 20 whose ends overlap the plate l6 and are provided with openings 2|. and edge clearances 22. For making the sand core plate M a pattern is used comprisi'nga base plate which is flat as a rule and on which the rib pattern is secured. The base plate is-fitted. with alining stops for arranging thereon and alining the metal plate 16 which is placed on the base. plate. In the mold thus formed the core plate is. produced in known manner from white core sandwith the aid of a plate or if necessary of a second pattern molding the topside of the core plate andafter separation from. the pattern united with the metal plate l6.

As-indicatedc by'dashes and dots in'Figs. 6 and 7,. thesand core parts projecting from the metal plate L6 can'be supported relative to one another after assembling in. the mold by means of projections 2-3 of rib thickness which. are positioned on the sides thereof and produce holes in the cast ribs. The provision of projections 23 for supporting the projecting portions of the sand core plates M in the mold makes it possible in some instances to dispense with the metal insertions 20'.

The pairs of core plates M, Hibetween the sand cores l3 have the same shape and are symmetrically arranged on both sides of a central rib, or of a hollow mold serving for forming it, whose thickness and form or edge are determined by a steel plate 24 insertedbetween the two adjoining core plates.

On the cores 13, or on the receiving ledges or projections provided on the insides of the walls of the molding box, sand core plates 25 are placed forming in pairs the hollow molds 2B of cast ribs which extend in planes disposed perpendicular to the cylinder axis and which meet at an angle the previously mentioned axially parallelly extending ribs. The core plates 25 are formed like the core plates 54, it.

On the set of core plates 25 extending up to the surface of the molding box another set of core plates Zl is piled which form the hollow molds iii of ribs extending in planes disposed perpendicular to the cylinder axis. On alining pins 29 inserted in a flange til of the molding box E2 the core plates 2'5 are placed with the openings provided in their metal plates 3!, SI, and on the plates 2? a plate 32 is put whichreceives the mold top, not shown, holds the core 33 for the bore and is fitted with the usual gate and risers.

The metal plates 3 i, 3 i are so arranged in pairs within one another that the lower plate 3! of each pair possesses on the outer edge an upwardly directed annular projection Bi and in the fiat depression thus formed on the upper side of the plate 3| the other plate 3! is inserted. As the height of the projection M of the plate 3| is somewhat less than the thickness of the inserted plate 3 l a small interstice through which gas and air can escape from the core plates exists between the top of the projection SI and the underside of the next plate fitted with a projection. Otherwise, the core plates composed of the metal plates 3!, 3| and the sand cores 2'! are similarl arranged and produced as the previously described core plates made up from the metal plates l6 and the sand core plates M which are positioned parallel to the cylinder axis. The joining of the metal plates 3i, 3| in pairs is advisable when the ribs have a small wall thickness and are slightly spaced to prevent distortion and deformation of the core plates whereby the accuracy to size of the casting would be affected. The arrangement described protects both plates, one by reinforcement of the edge and the other by being inserted in the first, against deformation.

In the construction shown in Figs. 8 and 9 the sand cores t l are anchored in their metal plates 35 by means of a groove 36 and of additional clearances 31 provided on the inner edge of the metal plates and fitted with reinforcements in the form of thin perforated metal plates. In the embodiment shown these reinforcements are constructed as ring sector plates 38 which when disposed on an outer side of the platelike sand cores 3i serve also for chilling the cast metal.

The construction of the core plate shown in Figs. 10 and 11 differs from the one just described only in so far as the reinforcements 39 are arranged so as to reinforce the inner edge of the sand core plate.

Further reinforcement of the thin-walled core plate is attained according to the invention by coating the finished and baked plate with linseed oil, dextrine, a sugar solution, collophony or similar hardenable substances.

Where the metal holding plates are of less thickness than the center to center distance between the ribs, it is necessary to insure accuracy of size of the casting in axial direction in spite 01 any possible deformation or wear of the metal plates during assembling of the mold from the various core plates. It is particularly important to insure this accuracy as to the casting, size in case of cylinders for two-cycle engines, cylinder heads for air-cooled aircraft engines and all work pieces having ports whose openings must be placed on an accurately determined level. To provide this accuracy in the present invention, the superposed oore plates, which are thicker than the metal holder plates, are relieved from the pressure produced by the assembling of the core plates by means of compression bars fixedly inserted in registering bores of the core plates. This arrangement is illustrated in Figs. 12 and 13 which show a core plate for an air-cooled two-cycle en gine cylinder and a section through a number of superposed plates on the line 13-!3, of Fig. 12. The metal holding plate 40 is of less thickness than the sand core plate ll and possesses a closed bore l2 and an edge clearance 43 for alining the core plates relative to one another. By inserting a rod in the clearances 43 subsequent alining of the plates is possible, so that in the building up of the mold, the plates can be relatively displaced as required for the insertion of the cores. The metal plate 40 has four bores 64 which are in register in the superposed core plates after alinernent. During construction of the mold, cylindrical members 45, Fig. 13, whose height is the same as the center to center spacing of the core ribs, are fixedly inserted in the bores M. In the finished mold the superposed members form continuous compression bars or struts which relieve the core plates of the weight of the top and insure accuracy to size of the casting in axial direction. It will be observed in Fig. 13

that members d5 hold the proximate faces of the holder plates in spaced relation to each other to thereby provide a space extending entirely around the mold for exposing the periphery of the core plate 4! to the atmosphere. Gas from the mold plates will therefore be permitted to escape. When the core plates are produced and used without metal holders, their openings 44 are preferably reinforced by inserted sleeves which may directly serve as spacing means it. The bores 42 and the clearances 4-3 are also suitably provided with a metal lining.

The core plates shown in Figs. 14 to 1'7 differ from those described in that for the purpose of establishing a firmer union of the sand portion and the metal portion the edges of the metal plate connecting with the sand portion are fitted with pins whose projecting parts are embedded in the platelike sand core. In the core plate shown in Figs. 14 and 15 and serving for forming the hollow mold for a short ribbed piece of the kind used at the upper part of a cylinder head, Fig. 5, the metal plate 48 has a rectangular outer edge corresponding to the form of the molding box in which it is inserted. The inner edge has a polygonal form corresponding to the outer edge 41 of the rib 48 which is to be molded thereby. Into a side face of the metal plate 46 flat grooves it are out which extend from the inner to the outer edge and serve for discharging air and gas from the sand mold. The polygonal inner edge of the metal plate 46 is undercut on both sides to clamp the edge of the sand core plate 53 to the metal plate. The edges 56, 5! of the plate 46 are bevelled so that the slope corresponds to the counter-templet.

The metal plates are provided on their inner edge where the sand core plate 53 is connected with pins 52 partly projecting from the plates parallel with the sides thereof. The pins 52 are spaced. approximatelyr'fll mn'lr though'this tance is preferably decreasing toward the outside: in the plate: shown in Fig. 14; When the, holes for-the pins'z have tube;drilledohliquelyinplaces. that are difficultly accessible; theprojecting; portions thereof are bent off into the: plane of the; plate.

The sand core 53 connected with the; pins. 5.2

has the same thickness as the metal-plate from the point adjoining the inner edge: ofthe. metal plate: up to the outer limiting; line of. the hollow rib space where the real core 48' connects which fills the space: between the two; ribs. The portion of the: core plate made of sand is reinforced by armoring insertions.

. In the constructionshown inFigs. 16,17 theannular metal plate 54 having a thickness equal to the spacing plus thickness of the ribs: is' provided. on the. inner edge with pins 55' spaced about; 20 mmwhose ends project. approximately mm. parallel with the side faces of the plate and areembedded in the. sandcore during connection of the, sand core plate;

Fig. 17 shows the bending of the projecting pin portions into theplane of the annular'platewhen the holesin which the pins are inserted are drilled obliquely.

I- claim:

1'. A mold comprisinga core; a group of super posed sand core plates disposed in face to face contact and positioned edgewise inspaced relation to said core, a metal holder plate secured remote from said coreto another edge of each sand core plate, and conduit means formed: between the metal plates'for permitting passage of gas and air from said core plates...

2. A moldcomprising, a core, a group of superposed sand. core plates disposed in face to face contact and positioned edgewise in spaced relation to said. core; a metal holder plate secured remote from said core to another edge of each sand core plate, said metalholder plates being of less thickness'than the attached sand core plates whereby conduits, are formed to permit passageof gas and air from said core plates, and means'for' holding said holder plates in a predetermined spaced relation.

A mold according to claim 1 wherein said conduit means comprises a groove formedv in the face oi at least one of the holder plates.

. 4. A. mold according to claim 2 wherein said lastrnamed means comprises registering. bores in said holder plates and extending perpendicular to the. plate faces, and a member of the. thickness of the associated sand core plate fixedly secured inthebore.

5-. A mold forribbed work pieces, as cylinder and cylinder heads. of air-cooled combustion engines, comprising a core member, a group of superposed core plates of sand disposed in face to face contact and having plate edge portions spaced from the proximate face of said core to thereby form a hollow space for receiving molten material, said plates having portions provided with parallel upper and lower faces, each plate edge portion disposed adjacent said core being oi less thcikness than at the parallel sided portions to provide rib forming grooves between the lastnamed plate edges, metal holder plates having the edges thereof respectively secured remote from said core to other edges of the sand core plates, and means comprisinga conduit formed between said holder plates for permitting the discharge of air and gas from said core and core plates.

6. A mold for ribbed work pieces, as cylinder and cylinder heads of air-cooled combustion engines, comprising a core member, a group of superposed core plates of sand disposed in face to face contact and having plate edge portions spaced from said core to thereby provide a recess for receiving molten. material for forming the cylinder, said plate having portions provided with parallelupper and lower faces, each plate edge portion disposed adjacent said core being of less thickness than at the parallel sided portions to form grooves between the core plate edges, a met alholder plate secured remote from said core to another edgeof each core plate, said holder plate beingof less thickness than the attached core plate whereby a. passageway between the proximate. faces of the holder plates will be formed to permit escape of gas and air from the core and core. plates, and means individual to each holder plate for maintaining the proximate faces of the latter in spaced relation.

ERNEST MAYER.

REFERENCES CITED The following references are of record in the file. ofv this patent;

UNITED STATES PATENTS Number Name Date 1,783,285 Goodwin Dec. 2, 1930 2,369,067v Mayer Feb. 6, 194.5 

